US10284136B1 - Narrow flashing for waterproof mounting of solar panels to a roof - Google Patents
Narrow flashing for waterproof mounting of solar panels to a roof Download PDFInfo
- Publication number
- US10284136B1 US10284136B1 US15/785,492 US201715785492A US10284136B1 US 10284136 B1 US10284136 B1 US 10284136B1 US 201715785492 A US201715785492 A US 201715785492A US 10284136 B1 US10284136 B1 US 10284136B1
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- United States
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- flashing
- disposed
- aperture
- pair
- flat
- Prior art date
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Links
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- 229920005549 butyl rubber Polymers 0.000 claims 1
- 239000000203 mixture Substances 0.000 abstract description 9
- 238000004078 waterproofing Methods 0.000 abstract description 3
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 12
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- 230000035515 penetration Effects 0.000 description 5
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- 229910000831 Steel Inorganic materials 0.000 description 2
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- 229920001296 polysiloxane Polymers 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
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Images
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S20/00—Supporting structures for PV modules
- H02S20/20—Supporting structures directly fixed to an immovable object
- H02S20/22—Supporting structures directly fixed to an immovable object specially adapted for buildings
- H02S20/23—Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/38—Connections for building structures in general
- E04B1/388—Separate connecting elements
-
- E04B1/40—
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/66—Sealings
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
- F24S25/61—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing to the ground or to building structures
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
- F24S25/63—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing modules or their peripheral frames to supporting elements
- F24S25/634—Clamps; Clips
- F24S25/636—Clamps; Clips clamping by screw-threaded elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/38—Connections for building structures in general
- E04B1/388—Separate connecting elements
- E04B2001/389—Brackets
-
- E04B2001/405—
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S2025/01—Special support components; Methods of use
- F24S2025/021—Sealing means between support elements and mounting surface
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
- F24S2025/6005—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules by screwed connection
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
- F24S2025/6006—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules by using threaded elements, e.g. stud bolts
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B10/00—Integration of renewable energy sources in buildings
- Y02B10/10—Photovoltaic [PV]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B10/00—Integration of renewable energy sources in buildings
- Y02B10/20—Solar thermal
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/40—Solar thermal energy, e.g. solar towers
- Y02E10/47—Mountings or tracking
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- This invention pertains to structures for mounting and attaching photovoltaic solar panels on roofs.
- flashing refers to a thin, generally flat sheet of metal or plastic or composite material that serves as part of an integrated system that waterproofs the mounting structures that hold photovoltaic solar panels on a roof, typically a pitched, composition shingle roof.
- the flashing serves as a replacement shingle that drains water off of the roof during a rainstorm.
- the flashing slips underneath the existing shingles at the point where a solar panel is mounted to the roof, typically above an underlying structural beam (rafter).
- Pipe vent flashings existed before solar attachment flashings, and were the basis for solar flashings. Flashing widths for pipe vent flashings were designed to provide water shedding for roof penetrations due to pipe vents.
- Pipe vents and thus roof penetrations due to pipe vents, range in diameter typically from one to four inches. Flashing widths for solar flashings should be designed to provide water shedding for roof penetrations due to lag bolts (solar system attachment purposes). Lag bolts are typically 5/16 inch in diameter. Since the diameters of lag bolts are significantly less than pipe vents, “solar” flashing used to flash lag bolts should be significantly narrower than pipe vent flashings. The length of a flashing is somewhat fixed due to the need for a flashing to extend into the third course of composition shingles.
- the aspect ratio of a solar flashing can be as high as 2.0, or more.
- the distance from the flashing aperture to the downslope edge of a typical solar flashing is 3 inches. Exposure of the roof penetration, at the attachment fastener, to rain, snow, snow melt, etc., is then 3 inches from the downslope edge of the flashing. In the present invention, one embodiment is to apply the 3 inch distance to the downslope edge to the edge distance to the sides of the flashing, resulting in a 6 inch wide flashing.
- flashings are typically made of stamped sheet metal, flashings can result in at least two problems: (1) dropping a flashing with a sharp corner onto a roof surface can result in the sharp corner penetrating or lancing an element of the roofing system/water sealing system, and (2) sharp corners can result in cuts to installers' hands, especially in retrofit applications (installation of flashing onto existing roofing systems), since an installer must forcefully insert a flashing under adhered and nailed composition shingles.
- the use of butyl tape has long been used in the roofing industry (attachment directly to composition shingles, interleaf on corrugated metal roofs, etc.).
- Flashing patents have also been granted to D-Three Enterprises (Zilla) for flashings with raised protrusions, including U.S. Pat. Nos. 8,661,765, 8,869,490, 8,479,455, 8,448,405, 9,068,339, 8,707,654, 8,707,655, 8,752,338, 8,833,032, 8,689,517, and 8,833,033.
- Improved versions of flat flashings are used for waterproofing mounting hardware that holds photovoltaic solar panels on a roof; typically, such a roof would be a pitched, composition shingle roof.
- the flashings are narrow in width and have chamfered and/or rounded corners, and a variety of alignment marks printed on the flashing for aligning the flashing with adjacent shingles.
- the height/width (H/W) aspect ratio of the flashing can range from 1.4 to 2.0, or more.
- FIG. 1 shows a top plan view of a first example of a flashing, according to the present invention.
- FIG. 2 shows a bottom plan view of the first example of a flashing, according to the present invention.
- FIG. 3 shows a side view of the first example of a flashing, according to the present invention.
- FIG. 4 shows a perspective view of the first example of a flashing, according to the present invention.
- FIG. 5 shows a top plan view of a second example of a narrow flashing, according to the present invention.
- FIG. 6 shows a bottom plan view of the second example of a narrow flashing, according to the present invention.
- FIG. 7 shows a side view of the second example of a narrow flashing, according to the present invention.
- FIG. 8 shows a perspective view of the second example of a narrow flashing, according to the present invention.
- FIG. 9 shows a perspective exploded view of a first example of a narrow flashing assembly, according to the present invention.
- FIG. 10 shows a perspective exploded view of a second example of a narrow flashing assembly, according to the present invention.
- the present invention relates to narrow flashings that are improved versions of flashings and are used for waterproofing mounting hardware that holds photovoltaic solar panels on a roof; typically, such a roof is a pitched, composition shingle roof.
- These narrow flashings are flat and have no raised protrusions. As such, they are less expensive to manufacture.
- Water sealing is accomplished through the use of a rubber, butyl, adhesive, or an EDPM washer, which is compressed underneath the head of a lag screw that screws through the roofing layers into an underlying rafter, and which is also used as a sealing pad disposed underneath a bracket (L-foot, slider bar, etc.) that is attached by the lag screw.
- the y-axis direction aligns with the long dimension of the flashing
- the x-axis aligns with the short dimension of the flashing, as indicated in the figures.
- the direction of a sloped roof is indicated in the figures as “slope”, and is parallel to the y-axis direction.
- the “downslope end” of the flashing refers to the bottom of the flashing when applied to a sloped roof
- the “upslope end” refers to the top of the flashing.
- FIG. 1 shows a top plan view of a first example of a flashing, according to the present invention.
- metal e.g., aluminum or aluminum alloy
- plastic e.g., polyethylene or polypropylene
- composite e.g., fiberglass, carbon fiber reinforced, or resin/sawdust mixture
- a minimum radius of the small rounded corner sections 17 of the chamfered and small rounded corners can be 0.1 inch.
- the corner radius, R can equal W/3, in this first example.
- a through-hole (aperture) 12 is located midway across flashing 10 , in the east-west direction, and approximately 1 ⁇ 4 of the way up from the Southern edge.
- a variety of alignment marks are printed on the surface of flashing 10 , including a pair of parallel alignment marks or bars 20 and 20 ′; a horizontal alignment mark or bar 22 located midway across flashing 10 in the east-west direction and located above the aperture 12 ; horizontal alignment marks or bars 26 located at opposite sides of the flashing 10 ; and a “cross” symbol 24 forming an alignment mark located midway across flashing 10 in the x-axis direction and located above the horizontal bar 22 .
- the use of cross symbol 24 aids in aligning the placement of a slider bar (not shown).
- the four marks that correspond with the center of the aperture 12 are used to aid in alignment with adjacent flashings both north/south and east/west.
- Horizontal alignment marks 20 , 20 ′, and 22 outline a square shape that matches the shape of a square elastomeric sealing pad (see FIG. 9 ).
- Cross symbol 24 is used to align the lower edge of composition tiles (shingles), which flashing 10 slides underneath when installed. The reason that these alignment marks are needed is that when a sealing pad (see FIG. 9 ) is applied to the bottom of a L-foot bracket (see FIG. 9 ), the aperture 12 in the flashing cannot be seen. If the marks align with the aperture in the L-foot or slider, the flashing aperture 12 will line up adequately with the aperture in the bracket.
- the height/width ratio (H/W) of flashing 10 is approximately equal to 1.4 for this first example. In other examples, the height/width ratio (H/W) of flashing 10 can be greater than or equal to 1.4. Flashing 10 is left/right symmetrical across a line drawn through the center of the flashing parallel to the y-axis. The radius, R, of the large rounded corners 14 is at least 5 times greater than the radius, r, of the small rounded corner sections 17 . The width, W, can be equal to or less than 7 inches.
- FIG. 2 shows a bottom plan view of a first example of a narrow flashing, according to the present invention.
- Flashing 10 has a printed feature 18 comprising an upside-down “U”-shape that encompasses the aperture 12 .
- the purpose of this printed feature 18 is to provide a printed mark that an installer can follow when applying liquid sealant/caulk (e.g., silicone caulk) to the bottom side of flashing 10 .
- liquid sealant/caulk e.g., silicone caulk
- the use of an upside-down “U”-shape is to provide a water dam (barrier) to deflect any flow of water from entering aperture 12 .
- One large rounded corner 14 and one chamfered section 16 are also indicated in FIG. 2 .
- FIG. 3 shows a side view of a first example of a narrow flashing, according to the present invention.
- the flashing 10 is flat in this view.
- FIG. 4 shows a perspective view of a first example of a narrow flashing, according to the present invention.
- Aperture 12 , and alignment marks 20 , 20 ′, 22 , 24 , and 26 , printed on flashing 10 can be seen.
- Chamfered section 16 and rounded corner 14 can be seen as well.
- FIG. 5 shows a top plan view of a second example of a narrow flashing, according to the present invention.
- the use of chamfered and/or rounded corners eliminates any problems associated with sharp corners.
- a through-hole (aperture) 12 is located midway across flashing 10 , in the east-west direction, and approximately 1 ⁇ 4 of the way up from the downslope edge.
- the diameter of aperture 12 can be oversized to allow for some misalignment of the lag screw.
- a variety of alignment marks are printed on the surface of flashing 10 , including a pair of parallel bars 20 and 20 ′, a horizontal alignment bar 22 located midway across flashing 10 in the east-west direction and located above the aperture 12 , and a “cross” symbol 24 located midway across flashing 10 in the east-west direction and above the horizontal bar 22 .
- the height/width ratio (H/W) of flashing 10 is approximately equal to 2.0 for this second example.
- the height/width ratio (H/W) of flashing 10 can be greater than or equal to 2.0.
- R the width of flashing 10
- the downslope end of flashing 10 contains two rounded corners 14 , 14 ′ that meet in the middle to form the semicircular shaped end.
- the radius, R, of the large rounded corners 14 , 14 ′ is at least 5 times greater than the radius, r, of the small rounded corner sections 17 .
- FIG. 6 shows a bottom plan view of the second example of a narrow flashing, according to the present invention.
- Flashing 10 has a printed feature 18 comprising an upside-down “U”-shape that encompasses the aperture 12 .
- the purpose of this printed feature 18 is to provide a printed mark that an installer can follow when applying liquid sealant/caulk (e.g., silicone caulk) to the bottom side of flashing 10 .
- the use of an upside-down “U”-shape for the sealant/caulk is to provide a water dam (barrier) to deflect any flow of water from entering aperture 12 .
- One chamfered section 16 is also indicated in FIG. 6 .
- FIG. 7 shows a side view of the second example of a narrow flashing 10 according to the present invention.
- the flashing 10 is flat in this view.
- FIG. 8 shows a perspective view of the second example of a narrow flashing 10 according to the present invention.
- Aperture 12 , and alignment marks 20 , 20 ′, 22 , 24 , and 26 , printed on flashing 10 can be seen.
- Chamfered section 16 and rounded corner 14 can be seen as well.
- FIG. 9 shows a perspective exploded view of a first example of a narrow flashing assembly, according to the present invention.
- Flashing 10 comprises an aperture 12 through which a lag screw 32 is mounted into an underlying structural support (not shown), which is used to mount an L-foot bracket 30 to the roof (not shown).
- An elastomeric (e.g., butyl) sealing pad 36 in the shape of a square that matches the bottom of L-foot 30 is disposed in-between the bottom of L-foot 30 and the upper surface of flashing 10 , which waterproofs the aperture 12 .
- An elastomeric (e.g., butyl) sealing pad 36 in the shape of a square that matches the bottom of L-foot 30 is disposed in-between the bottom of L-foot 30 and the upper surface of flashing 10 , which waterproofs the aperture 12 .
- EDPM EDPM
- Flashing 10 comprises a semi-circular, downslope end 14 .
- elastomeric sealing pad 36 can be made of a structural adhesive material, such as a DOW-321 adhesive, or 3M-2110, 2204, or 4110 adhesive tapes (which have been used to attach structural rails to dual-glass PV modules).
- An adhesion promoter such as Isopropyl Alcohol (IPA), can be used to promote robustness of the adhesive bond.
- IPA Isopropyl Alcohol
- FIG. 10 shows a perspective exploded view of a second example of a narrow flashing assembly, according to the present invention.
- Flashing 10 comprises an aperture 12 through which a lag screw 32 is mounted into an underlying structural support (not shown), which is used to mount a slider bar 40 to the roof (not shown).
- a rectangular, elastomeric (e.g., butyl) sealing pad 36 is disposed between the bottom of slider bar 40 and the upper surface of flashing 10 , which waterproofs the aperture 12 .
- An elastomeric (e.g. EDPM) washer 34 with a circular steel cap is disposed between the head of lag screw 32 and slider bar 40 through a second aperture 38 .
- Flashing 10 comprises a semi-circular, downslope end 14 .
- elastomeric sealing pad 36 can be made of a structural adhesive material, such as a DOW-321 adhesive, or 3M-2110, 2204, or 4110 adhesive tapes (which have been used to attach structural rails to dual-glass PV modules).
- An adhesion promoter such as Isopropyl Alcohol (IPA), can be used to promote robustness of the adhesive bond.
- a semi-circular downslope end 14 of the flashing is also indicated in FIG. 10 .
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Abstract
Description
Claims (23)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US15/785,492 US10284136B1 (en) | 2017-10-17 | 2017-10-17 | Narrow flashing for waterproof mounting of solar panels to a roof |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US15/785,492 US10284136B1 (en) | 2017-10-17 | 2017-10-17 | Narrow flashing for waterproof mounting of solar panels to a roof |
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US20190115866A1 US20190115866A1 (en) | 2019-04-18 |
US10284136B1 true US10284136B1 (en) | 2019-05-07 |
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US15/785,492 Active US10284136B1 (en) | 2017-10-17 | 2017-10-17 | Narrow flashing for waterproof mounting of solar panels to a roof |
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US20230283225A1 (en) * | 2020-10-14 | 2023-09-07 | GAF Energy LLC | Mounting apparatus for photovoltaic modules |
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US11824487B2 (en) | 2020-11-13 | 2023-11-21 | GAF Energy LLC | Photovoltaic module systems and methods |
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